Structural glazing spacer

ABSTRACT

A method of preparing a window module includes providing a metal frame having a first major surface, applying a structural glazing tape to the first major surface of the metal frame, and positioning a glass panel overtop the structural glazing tape. The structural glazing tape includes a polymer foam tape having first and second major surfaces, an adhesive layer overlying the first major surface for bonding the structural glazing tape to the structural frame, and a release layer overlying the second major surface. The method further includes filling a channel defined by the glass panel, the metal frame, and the structural glazing tape with a curable sealant, and curing the sealant to bond the glass panel and the metal frame together.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a continuation and claims priority to U.S. patentapplication Ser. No. 13/337,048 filed Dec. 23, 2011, entitled“STRUCTURAL GLAZING SPACER,” naming inventors Thomas A. Veilleux, JamesN. Gordon, and Stewart B. Dittmeier, which claims priority from U.S.Provisional Patent Application No. 61/427,105, filed Dec. 23, 2010,entitled “STRUCTURAL GLAZING SPACER,” naming inventors Thomas A.Veilleux, James N. Gordon, and Stewart B. Dittmeier, of which bothapplications are incorporated by reference herein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a structural glazing spacer.

BACKGROUND

Structural glazing can allow for the production of a glass facadewithout framing elements separating the glass panels from one another.Glass panels are mounted on a respective concealed peripheral frame andthen secured to the supporting structural framing. Sealing betweenadjacent glass panels and between the panels and the structural framingis performed by means of silicone sealant. The sealant can bond theglass panel to the structural framing to hold the glass in place.

Structural glazing systems make it possible to obtain continuous glazedfacades in which the various glass panels are spaced from one another byvery narrow gaps, having a width of the order of 15 mm, usually fully orpartly occupied by a silicone sealant, which produces a regularchecker-like partition among the glass panels.

Typically, the glass is positioned relative to the frame with a spacer,such as an extruded polymer or a foam tape. The spacer maintains a gapbetween the glass panel and the frame which can be filled with thesilicone sealant to form a strong bond between the frame and the glasspanel. The spacer remains within the module and can be visible throughthe glass. There is an ongoing need for improved spacers that can couplethe desired aesthetic appearance and ease of installation.

SUMMARY

In a first aspect, a structural glazing tape can include a polymer foamtape, an adhesive layer overlying a first major surface of the polymerfoam tape, and a release layer overlying a second major surface of thepolymer foam tape. The structural glazing tape can be used as a spacerbetween a structural frame and a glass panel. The spacer can provide aspace for a sealant to bond the structural frame and the glass paneltogether. The structural glazing tape can have a width in a range ofabout 3 mm to about 50 mm, such as about 6 mm to about 25 mm. In aparticular embodiment, the structural glazing tape can be provided inthe form of a roll, and the roll can be substantially free of aremovable liner.

In an embodiment of the first aspect, the polymer foam tape can includea polyurethane foam, a polyvinyl chloride foam, a silicone foam, anethylene propylene diene monomer rubber foam, an acrylic foam, apolychloroprene (Neoprene®) foam, a foam blend of EPDM rubber andpolypropylene, such as Santoprene® foam, a polyethylene foam, anethylvinyl acetate foam, or any combination thereof. The polymer foamcan have a force to compress at 10% in a range of about 10 kPa to about500 kPa, such as about 50 kPa to about 300 kPa. The polymer foam canhave a thickness in a range of about 2 mm to about 12 mm.

In another embodiment of the first aspect, the adhesive can be apressure sensitive adhesive, such as a rubber-based adhesive, anacrylic-based adhesive, a silicone-based adhesive, a silylatedpolyurethane, or any combination thereof. The adhesive layer can have athickness in a range of about 0.01 mm to about 0.25 mm.

In yet another embodiment of the first aspect, the release layer caninclude a release agent, such as a silicone-based material, afluorine-based material, a long-chain alkyl-based material, a fatty acidamide-based material, a polyvinyl alcohol-based material, a silicapowder material, or any combination thereof. The release layer can havea thickness in a range of about 0.003 m to about 50 m.

In a particular embodiment, the structural glazing tape can also includea barrier layer, a UV/stabilizer layer, a colorant layer, or acombination thereof between the polymer foam and the release layer.

In still another embodiment of the first aspect, the structural glazingtape can also include a polymer film between the polymer foam and therelease layer. The polymer film can include a polyethylene, apolyurethane, a polyacrylate, a polymethacrylate, a polyester, or anycombination thereof. In a particular embodiment, the polymer film caninclude a polyethylene terephthalate. Additionally, the polymer film mayinclude a pigment. In a particular embodiment, the structural glazingtape can also include a pigment layer between the polymer foam and thepolymer film. The pigment layer can include a polymer and a pigment.

In a further embodiment of the first aspect, the structural glazing tapecan have an Unwinding Peel Strength in a range of about 0.01 lb/in toabout 2.5 lb/in, such as in a range of about 0.10 lb/in to about 1.5lb/in. Further, the structural glazing tape can have a peel strengthfrom a stainless steel panel in a range of about 1.0 lb/in to about 8.0lb/in, such as in a range of about 2.0 lb/in to about 6.0 lb/in.

In a second aspect, a window module can include a metal frame, a glasspanel, a structural glazing tape between a first major surface of themetal frame and a second major surface of the glass panel, and a curedsealant between the first major surface of the metal frame and thesecond major surface of the glass panel and adjacent to the structuralglazing tape. The structural glazing tape can include a polymer foamtape, an adhesive layer overlying a first major surface of the polymerfoam tape and a release layer overlying the second major surface of thepolymer foam tape. The adhesive layer can bond the structural glazingtape to the first major surface of the structural frame, and the releaselayer can be positioned adjacent to the second major surface of theglass panel. The cured sealant can bond the metal frame to the glasspanel.

In an embodiment of the second aspect, the glass panel can include oneglass pane. In another embodiment, the glass panel can include aninsulated glass including at least two glass panes. The metal frame caninclude an extruded aluminum. The sealant can include a siliconesealant.

In a third aspect, a method of preparing a window module can includeproviding a metal frame having a first major surface, applying astructural glazing tape to the first major surface of the metal frame,and positioning a glass panel on the structural glazing tape. Thestructural glazing tape can include a polymer foam tape, an adhesivelayer overlying a first major surface of the polymer foam tape, and arelease layer overlying a second major surface of the polymer foam tape.The adhesive layer can bond the structural glazing tape to thestructural frame. The method can further include filling a space with acurable sealant, and curing the sealant to bond the glass panel and themetal frame together. The space can be defined by the glass panel, themetal frame, and the structural glazing tape.

In an embodiment of the third aspect, the glass panel can include oneglass pane. In another embodiment, the glass panel can include aninsulated glass including at least two glass panes. The metal frame aninclude an extruded aluminum. The sealant can include a siliconesealant.

In another embodiment of the third aspect, curing the sealant caninclude heating the sealant to a cure temperature, reacting the sealantwith moisture in the air, directing electromagnetic radiation at thesealant, or any combination thereof. The electromagnetic radiation caninclude ultraviolet radiation.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIGS. 1 through 3 show cross sections of exemplary structural glazingtapes according to aspects of the present disclosure.

FIGS. 4 and 5 show a cross section of exemplary window modules accordingto aspects of the present disclosure.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

In an embodiment, a structural glazing tape can be used as a temporaryassembly aid to create a space between a metal frame and a glass panel.The space can be suitable for applying a sealing to bond the glass panelto the metal frame. The structural glazing tape can have an adhesive onone side for bonding to the metal frame and a release layer on the otherside. The release layer can substantially prevent the structural glazingtape from bonding to itself without the use of a liner when supplied ina roll.

FIG. 1 illustrates a cross-sectional view of an exemplary structuralglazing tape 100. The structural glazing tape 100 can include a polymerfoam 102. The polymer foam 102 can have major surfaces 104 and 106.Further, the structural glazing tape 100 can include an adhesive layer108 overlying major surface 104 and a release layer 110 overlying majorsurface 106. The structural glazing tape 100 can include a barrier layer112 between the polymer foam 102 and the release layer 110. The barrierlayer can include a polymer resistant to solvents and substantiallyreduces or substantially prevents migration of chemicals and solventspresent in the release layer 110 into polymer foam 102. The structuralglazing tape 100 can further include other layers, films, or coatings(not illustrated in FIG. 1) as well. For example, the structural glazingtape 100 can further include a polymer layer, a colorant layer, U/Vstabilizer layer, or a combination thereof (not illustrated in FIG. 1).The colorant layer can include a polymer and a pigment to impart andmaintain an aesthetically pleasing color to the structural glazing tape100. Additionally, a pigment in the colorant layer can substantiallyprevent or attenuate color changes in the polymer foam 102 due to aging,or hide color changes.

The polymer foam 102 can include a polyurethane foam, a polyvinylchloride foam, a silicone foam, an ethylene propylene diene monomer(EPDM) rubber foam, an acrylic foam, a polychloroprene foam,polychloroprene foam, a foam blend of EPDM rubber and polypropylene, apolyethylene foam, a ethylvinyl acetate foam, or any combinationthereof. The polymer foam 102 can provide a sufficient thickness tocreate a space between a metal frame and a glass panel so that a sealantcan be applied to bond the metal frame and the glass panel together. Inan exemplary embodiment, the polymer foam can have a thickness in arange of about 2 mm to about 12 mm.

Additionally, the polymer foam 102 can be partially compressible toenable the structural glazing tape to conform to the surfaces of themetal frame and the glass panel while still maintaining sufficient spacebetween the glass panel and the metal frame for the sealant. In anexemplary embodiment, the polymer foam can have a force to compress at10% in a range of about 10 kPa to about 500 kPa, such as about 50 kPa toabout 300 kPa.

The adhesive layer 108 can include an adhesive, such as a pressuresensitive adhesive. The pressure sensitive adhesive can include arubber-based adhesive, an acrylic-based adhesive, a silicone-basedadhesive, a silylated polyurethane, combinations thereof, and the like.The adhesive layer 108 can provide sufficient adhesion to hold thestructural glazing tape 100 in place during positioning of the glasspanel as well as during application and curing of the sealant. In anexemplary embodiment, the adhesive layer can have a thickness in a rangeof about 0.01 mm to about 0.25 mm.

The adhesive polymer may further include additives to impart particularproperties on the adhesive polymer. For instance, pigments, fillers,catalyst, plasticizer, biocide, flame retardant, antioxidant,surfactant, tackifiers, adhesion promoting additives, and the like maybe added. Exemplary pigments include organic and inorganic pigments.Suitable fillers include, for instance, silica, precipitated silica,talc, calcium carbonates, aluminasilicates, clay, zeolites, ceramics,mica, aluminium or magnesium oxide, quartz, diatomaceous earth, thermalsilica, also called pyrogenic silica, and nonpyrogenic silica. Thefillers may also be silicates such as talc, mica, kaolin, glassmicrospheres, or other mineral powders such as calcium carbonate,mineral fibers, or any combination thereof. Exemplary plasticizersinclude paraffinic oils, naphthenic oils, low molecular weightpoly-1-butene, low molecular weight polyisobutene, and combinationsthereof. In a particular embodiment, the foamed polymer includesadhesion promoting additives such as functional silanes or otheradhesion promoters. Exemplary silanes include 3-aminopropyltrimethoxysilane, 3-(trimethoxysilyl)propyl methacrylate,3-glycidoxypropyltrimethoxy silane, and n-ocryltrimethoxy silane. Theadhesion promoter may optionally be used in an amount of about 0.0001%to about 5.0%, for example from about 0.01% to about 2.0% by weight ofpolymer.

The release layer 110 can include a composition immiscible with thepressure sensitive adhesive. The release layer 110 can be in directcontact with the adhesive layer 108 when the structural glazing tape 100is provided in a roll, and the release layer 110 can be easily separatedfrom the adhesive layer 108. As such, the release layer 110 cansubstantially eliminate the need for a liner to be placed over theadhesive layer 108 that would otherwise need to be removed when applyingthe structural glazing tape 100 to the metal frame. The release agentmay include a colorant or a U/V stabilizer.

For example, the release layer 110 can include a release agent,silicone-based material, a fluorine-based material, a long-chainalkyl-based material, a fatty acid amide-based material, a polyvinylalcohol-based material, a silica powder material, or any combinationthereof. An example release agent is a silicone-based release agent,such as an addition-curable and condensation curable silicone. In thistype of release material, a platinum (Pt) or rhodium (Rh) catalyst isused in general as the curing catalyst for the release agent. In anembodiment, the fluorine-based material can include fluoropolymers. Inone particular embodiment, the fluorine-based material can includepolytetrafluoroethylene (PTFE).

Alternatively, the release layer 110 can be formed of greases or oilsthat maintain some viscosity. For example, the release material caninclude a silicone grease, a fluorosilicone oil, a phenylsilicone oil, aparaffin wax, or any combination thereof.

The release layer 110 can further be formed from an aqueous precursor.The aqueous precursor includes the release agent in an aqueous medium.The release layer 110 is then formed by applying the aqueous precursoronto the surface underlying the release layer followed by dehydration ofthe precursor. Optionally, curing can follow the dehydration. Afterdehydration or curing, the release layer is formed.

Alternatively, the release layer 110 can be formed from an non-aqueousprecursor. The non-aqueous precursor includes the release agent in anon-aqueous solvent. Solvents can include methyl ethyl ketone, isopropylalcohol, acetone, toluene, methyl isobutyl ketone, or any combinationthereof. The release layer 110 is then formed by applying thenon-aqueous precursor onto the surface underlying the release layerfollowed by removal of the non-aqueous solvent. Optionally, curing canfollow the removal of the solvent. After solvent removal or curing, therelease layer is formed.

In an exemplary embodiment, the release layer can have a thickness in arange of about 0.003 m to about 50 m.

The release layer may also include a filler, such as a solid lubricant,a ceramic or mineral filler, a polymer filler, a fiber filler, a metalparticulate filler or salts or any combination thereof. An exemplarysolid lubricant includes polytetrafluoroethylene or a solid lubricantselected from molybdenum disulfide, tungsten disulfide, graphite,graphene, expanded graphite, boron nitride, talc, calcium fluoride,cerium fluoride, or any combination thereof. An exemplary ceramic ormineral includes alumina, silica, titanium dioxide, calcium fluoride,boron nitride, mica, Wollastonite, silicon carbide, silicon nitride,zirconia, carbon black, pigments, or any combination thereof. Anexemplary polymer filler includes polyimide, Ekonol® polyester,polybenzimidazole, any of the thermoplastic polymers listed above, orany combination thereof. An exemplary fiber includes nylon fibers, glassfibers, carbon fibers, polyacrylonitrile fibers, polyaramid fibers,polytetrafluoroethylene fibers, basalt fibers, graphite fibers, ceramicfibers, or any combination thereof. Exemplary metals include bronze,copper, stainless steel, or any combination thereof. An exemplary saltincludes a sulfate, a sulfide, a phosphate, or any combination thereof.

In a particular embodiment, the release agent can be chosen to minimizeundesirable optical effects when the release agent is in contact withthe glass. Additionally, an exposed surface of the release layer can betextured or fillers can be incorporated into the release layer tofurther reduce the optical effects.

FIG. 2 illustrates a cross-sectional view of another exemplarystructural glazing tape 200. The structural glazing tape 200 can includea polymer foam 202. The polymer foam 202 can have major surfaces 204 and206. Further, the structural glazing tape 200 can include an adhesivelayer 208 overlying major surface 204. A polymer film 218 can overliemajor surface 206. Additionally, a release layer 210 can overlie thepolymer film 218. Optionally, the structural glazing tape 200 caninclude a colorant layer 212 between the polymer foam 202 and thepolymer film 218. In an alternate embodiment (not illustrated in FIG.2), the colorant layer can be between release layer 210 and polymer film218.

Polymer film 218 can include a polymer, such as a polyethylene, apolyurethane, a polyacrylate, a polymethacrylate, a polyester, or anycombination thereof. In a particular embodiment, the polymer can includea polyethylene terephthalate (PET). The polymer film can include apigment or a U/V stabilizer. The pigment can serve to substantiallyprevent color changes due to aging of the polymer foam 202 from beingvisible. Alternatively, the polymer film can be substantiallytransparent, and the optional colorant layer 212 can substantiallyobscure color changes in the polymer foam 202. Optionally, there can bean additional adhesive layer between the polymer foam 202 and thepolymer film 218. The additional adhesive layer can include an adhesivesuitable for increasing the adhesion between the polymer film 218 andthe polymer foam 202. The additional adhesive layer can be combined withthe colorant layer 212, such as by adding a pigment as a filler to theadditional adhesive layer, or the additional adhesive layer can beseparate from the optional colorant layer 212.

In an embodiment, the tape can be provided in a roll such that the tapecan be unwound from the roll without undue force. For example, the tapecan have an Unwinding Peel Strength in a range of about 0.01 lb/in toabout 2.0 lb/in, such as about 0.01 lb/in to about 1.0 lb/in, or in arange of about 0.10 lb/in to about 0.5 lb/in, measured according to theforce required to remove the tape directly from the roll. The UnwindingPeel Strength can be determined by measuring “T” Peel Strength at a rateof 40 inches/min according to ASTM D1876. Additionally, after removalfrom the roll, the tape should have sufficient adhesive strength toadhere to a surface, such as a metal frame. For example, the tape canhave a peel strength from a stainless steel panel in a range of about1.0 lb/in to about 8.0 lb/in, such as in a range of about 2.0 lb/in toabout 6.0 lb/in. The peel strength from a stainless steel panel can bedetermined by measuring the 90-degree peel strength at 12 inches/minaccording to ASTM D1000-99, using a segment of tape unwound from theroll and laminated onto stainless steel panel.

FIG. 3 illustrates a cross-sectional view of an exemplary structuralglazing tape 300. The structural glazing tape 300 can include a polymerfoam 302. The polymer foam 302 can have major surfaces 304 and 306.Further, the structural glazing tape 300 can include an adhesive layer308 overlying major surface 304 and a release layer 310 overlying majorsurface 306. Optionally, the structural glazing tape 300 can includeadditional layers or a coating between the polymer foam 302 and therelease layer 310. The additional layer or coating can include a polymerto impart a barrier between the polymer foam 302 and the release layer310. In another embodiment, the additional layer or coating can includea polymer including a colorant or pigment to impart aestheticallypleasing color to the structural glazing tape 300. Additionally, thepigment layer can substantially prevent color changes in the polymerfoam 302 due to aging from being visible.

The polymer foam 302 can include foamed polymers, dimensions, andproperties as described for polymer foam 102 in FIG. 1. The adhesivelayer 308 can include compounds, dimensions, and properties as describedfor adhesive layer 108 in FIG. 1.

The release layer 310 can include a composition immiscible with thepressure sensitive adhesive. The release layer 310 can be in directcontact with the adhesive layer 308 when the structural glazing tape 300is provided in a roll, and at least a portion of the release layer 310can be easily separated from the adhesive layer 308. As such, therelease layer 310 can substantially eliminate the need for a liner to beplaced over the adhesive layer 308 that would otherwise need to beremoved when applying the structural glazing tape 300 to the metalframe. Moreover, the release layer 310 becomes a permanent component ofglazing tape 300 when placed between a frame and glass panel as furtherdescribed herein.

For example, the release layer 310 can include a release agent,silicone-based material, a fluorine-based material, a long-chainalkyl-based material, a fatty acid amide-based material, a polyvinylalcohol-based material, a silica powder material, or any combinationthereof. An example release agent is a silicone-based release agent,such as an addition-curable and condensation curable silicone. In thistype of release material, a platinum (Pt) or rhodium (Rh) catalyst isused in general as the curing catalyst for the release agent.

Alternatively, the release layer 310 can be formed of greases or oilsthat maintain some viscosity. For example, the release material caninclude a silicone grease, a fluorosilicone oil, a phenylsilicone oil, aparaffin wax, or any combination thereof. Moreover, the release layercan include a solvent to modify viscosity. For release layers includinga solvent, an additional barrier layer between can be present betweenrelease layer 310 and polymer foam 302 to substantially preventmigration of solvent from the release layer 310 into the polymer foam302. The barrier layer can include a water-based polyurethane polymer.In another embodiment, the barrier layer can include an acrylic polymer,or a wax.

In an exemplary embodiment, the release layer can have a thickness in arange of about 0.003 m to about 50 m. In another embodiment, the releaselayer has a thickness of at least 0.3 μm.

The release layer 310 may also include a filler, such as a solidlubricant, a ceramic or mineral filler, a polymer filler, a fiberfiller, a metal particulate filler or salts or any combination thereof.An exemplary solid lubricant includes polytetrafluoroethylene or a solidlubricant selected from molybdenum disulfide, tungsten disulfide,graphite, graphene, expanded graphite, boron nitride, talc, calciumfluoride, cerium fluoride, or any combination thereof. An exemplaryceramic or mineral includes alumina, silica, titanium dioxide, calciumfluoride, boron nitride, mica, Wollastonite, silicon carbide, siliconnitride, zirconia, carbon black, pigments, or any combination thereof.An exemplary polymer filler includes polyimide, Ekonol® polyester,polybenzimidazole, any of the thermoplastic polymers listed above, orany combination thereof. An exemplary fiber includes nylon fibers, glassfibers, carbon fibers, polyacrylonitrile fibers, polyaramid fibers,polytetrafluoroethylene fibers, basalt fibers, graphite fibers, ceramicfibers, or any combination thereof. Exemplary metals include bronze,copper, stainless steel, or any combination thereof. An exemplary saltincludes a sulfate, a sulfide, a phosphate, or any combination thereof.

In a particular embodiment, the release agent can be chosen to minimizeundesirable optical effects when the release agent is in contact withthe glass. Additionally, an exposed surface of the release layer can betextured or fillers can be incorporated into the release layer tofurther reduce the optical effects.

FIG. 4 illustrates a cross sectional view of an exemplary structuralmodule 400. Structural module 400 can include a frame 402 and a glasspanel 404. Between the frame 402 and the glass panel 404 can be a spacer406, such as structural glazing tape 100, 200, or 300. The spacer 406can include an adhesive 408 adjacent to the frame 402 to bond the spacer406 to the frame 402. Additionally, the spacer 406 can include a releaselayer 410. The release layer 410 can be adjacent to the glass panel 404when assembled within the module 400. Additionally, the structuralmodule 400 can include a sealant 412 to bond the glass panel 404 to theframe 402. As can be seen in FIG. 4, the release layer is integratedinto the structural glazing tape when the tape is deployed into a windowmodule 400 between the frame 402 and the glass panel 404. Alternativelystated, the release layer 410 is a permanent, non-removable feature ofthe structural glazing tape that is directly or indirectly bonded to thepolymer foam from the tape, unlike a releasable liner, which is removedprior to deployment. As should be clear, various embodiments herein aredirected to self-wound tapes, having a liner-free construction and anintegrated release layer in the structural glazing tape.

The frame 402 can include a metal, a polymer, or any combinationthereof. In a particular embodiment, the frame can be an extruded metalor polymer. The frame 402 can provide support for the glass panel 404and can serve as an attachment point to the structural framing of abuilding or other structure.

The glass panel 404 can include one or more panes of glass. In aparticular embodiment, the glass panel can be a single pane glass.Alternatively, the glass panel can include two or more panes and can bean insulated glass, further serving to reduce heat flow between anexterior of the structural module 400 and the interior of the structuralmodule 400.

The sealant 412 can include a curable polymer. In an embodiment, thecurable polymer can be a moisture-cured polymer, a thermally-curedpolymer, or a radiation-cured polymer. For example, curing of a moisturecured polymer can be initiated by exposure to moisture in the air. Inanother example, curing of a thermally-cured polymer can be initiated byheating the polymer to a curing temperature, and curing of aradiation-cured polymer can be initiated by exposing the polymer toelectromagnetic radiation, such as ultra-violet (UV) radiation. In anembodiment, the curable polymer can be a silicone polymer.

After curing, the curable polymer can serve to bond the glass panel andthe frame together. The adhesion of the curable polymer can besufficient to substantially prevent the glass panel from moving relativeto the frame even when the structural module is placed in a verticalposition and the weight of the glass panel produces a sheering forcebetween the glass panel and the frame. Additionally, the sealant cansubstantially prevent environmental elements, such as air, water, anddust, from penetrating the structural module and passing either from aninterior to exterior space or from an exterior to interior space.

FIG. 5 illustrates a cross sectional view of another exemplarystructural module 500. Structural module 500 can include a frame 502 anda glass panel 504. Between the frame 502 and the glass panel 504 can bea spacer 506, such as structural glazing tape 100, 200, or 300. Thespacer 506 can include an adhesive 508 adjacent to the frame 402 to bondthe spacer 506 to the frame 502. Additionally, the spacer 506 caninclude a barrier layer 514 and a release layer 510. The release layer510 can be adjacent to the glass panel 504 when assembled within themodule 500. The barrier layer 514 can be between spacer 506 and releaselayer 510. Additionally, the structural module 500 can include a sealant512 to bond the glass panel 504 to the frame 502.

The frame 502 can include materials as described for frame 402 in FIG.4. The glass panel 504 can include one or more panes of glass asdescribed for glass panel 404 in FIG. 4. The sealant 512 can includematerials as described for sealant 412 in FIG. 4.

The barrier layer 514 protects spacer 506 from solvents and or liquidsthat are included in release layer 510. As described above, solvents maybe present in release layers 210 or 110. When solvents or liquids arepresent in the release layers, a barrier layer, such as barrier layer112 in FIG. 1, becomes in the window module barrier layer 514 which isplaced underneath release layer 510. The barrier layer 514 substantiallyreduces or substantially prevents migration of chemicals or solventspresent in release layer 510 into spacer 506. The barrier layer 514 caninclude materials such as described for layer 112 in glazing tape 100.

Turning to the method of forming the structural glazing tape, a releaseagent can be applied to a support to form a release layer. In aparticular embodiment, an optional colorant layer can be appliedoverlying the release layer. Additionally, a polymer foam precursor canbe mixed with a foaming agent and then spread onto the support overlyingthe release layer and optionally, the colorant layer. The polymer foamprecursor can be cured to form a polymer foam, and an adhesive layer canbe applied overlying the polymer foam. In an embodiment, the foam can becut to form a tape including the release layer, the foam, and theadhesive, and the tape can be rolled onto a roll without interleaving aliner between wrappings of the tape. Rather, the release layer can serveto substantially prevent the adhesive layer from sticking to theprevious wrapping of the tape.

In another embodiment, the polymer foam precursor can be mixed with afoaming agent and spread onto a polymer film, such as a PET film. Thepolymer film can include a release coat on the side opposite of thepolymer foam precursor. The polymer film can be a colored film or aclear film. In a particular embodiment, the clear film can be coatedwith an optional colorant layer prior to spreading the polymer foamprecursor. The polymer foam precursor can be cured to form a polymerfoam and coated with an adhesive. The structure can be cut to a desiredsize, such as a tape having a width of between about and about 3 mm toabout 50 mm. Additionally, the tape can be rolled onto a roll withoutinterleaving a liner between wrappings of the tape.

In a further embodiment, an additional adhesive layer can be locatedbetween the polymer foam and the polymer film to increase adhesionbetween the polymer foam and the polymer film. For example, the adhesivecan be applied to a PET film and the polymer foam precursor can beapplied overtop the adhesive. Alternatively, the PET film can be bondedto the polymer foam with the polymer foam after forming the polymerfoam.

Turning to the method of assembling the structural module, a frame canbe assembled. The frame can include an extruded aluminum. A structuralglazing tape can be applied to a surface of the frame, such that thestructural glazing tape only covers a portion of the surface. Thestructural glazing tape can be applied such that an adhesive layer ofthe structural glazing tape adheres to the frame. A glass panel can beapplied overtop the structural glazing tape. A release layer of thestructural glazing tape can be in contact with a surface of the glasspanel. Due to the lack of adhesion between the release layer and theglass panel, the position of the glass panel can be adjusted as needed.The glass panel, the structural glazing tape, and the surface of theframe can define a channel. Depending on the initial positioning of thestructural glazing tape on the frame, the channel can be interior of thestructural glazing tape or exterior to the structural glazing tape. Asealant, such as a silicone sealant, can be applied to fill the channel.Additionally, the sealant can be cured, such as by applying heat,electromagnetic radiation, or moisture to the sealant. Upon curing thesealant can bond the glass panel to the frame.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofinvention.

A structural glazing tape can be for use as a spacer between astructural frame and a glass panel to provide a space for a sealant tobond the structural frame and the glass panel together. The structuralglazing tape can include a polymer foam tape having first and secondmajor surfaces, an adhesive layer overlying the first major surface forbonding the structural glazing tape to the structural frame, and arelease layer overlying the second major surface. The release layer canbe integrated into the structural glazing tape such that the releaselayer is present between the structural frame and the glass panel whendeployed.

A structural glazing tape for use as a spacer between a structural frameand a glass panel to provide a space for a sealant to bond thestructural frame and the glass panel together can include a polymer foamtape having first and second major surfaces, an adhesive layer overlyingthe first major surface for bonding the structural glazing tape to thestructural frame, and a release layer overlying the second majorsurface. The release layer can substantially prevents the structuralglazing tape from bonding to itself. The structural glazing tape can befree of a liner.

In one embodiment, the polymer foam tape can include a polyurethanefoam, a polyvinyl chloride foam, a silicone foam, an ethylene propylenediene monomer rubber foam, an acrylic foam, a polychloroprene foam, afoam blend of EPDM rubber and polypropylene, a polyethylene foam, anethylvinyl acetate foam, or any combination thereof. In anotherembodiment, the adhesive is a pressure sensitive adhesive. The pressuresensitive adhesive includes a rubber-based adhesive, an acrylic-basedadhesive, a silicone-based adhesive, a silylated polyurethane, or anycombination thereof.

In one embodiment, the release layer is formed form an aqueousprecursor. The release layer can include a release agent. The releaseagent can include a silicone-based material, a fluorine-based material,a long-chain alkyl-based material, a fatty acid amide-based material, apolyvinyl alcohol-based material, a silica powder material, or anycombination thereof. The fluorine-based material can includepolytetrafluoroethylene (PTFE).

In one embodiment, the structural glazing tape can further include abarrier layer between the polymer foam and the release layer. Thebarrier layer functions to seal the second major surface from materialforming the release layer. In one embodiment, the barrier layer has athickness of at least 0.5 microns, such as at least about 1 micron, orat least about 2 microns. In another embodiment, the barrier layer has athickness of not greater than about 25 microns, such as not greater thanabout 20 microns, or not greater than about 12 microns. The barrierlayer can include a polyurethane, acrylic polymer, or wax.

In another embodiment, the release layer of the structural glazing tapeis formed form a non-aqueous precursor. The precursor can include arelease agent. The release agent includes a silicone-based material, afluorine-based material, a long-chain alkyl-based material, a fatty acidamide-based material, a polyvinyl alcohol-based material, a silicapowder material, or any combination thereof. In one embodiment, thefluorine-based material includes polytetrafluoroethylene (PTFE). Inanother embodiment, the non-aqueous precursor can include a non-aqueoussolvent.

In one embodiment, the structural glazing tape can further include apolymer film between the polymer foam and the release layer. The polymerfilm has a thickness of between about 25 microns and about 508 microns.In another embodiment, the polymer film has a thickness of between about76 microns and about 254 microns. In yet another embodiment, the polymerfilm has a thickness of at least about 127 microns. The polymer film caninclude a polyethylene, a polyurethane, a polyacrylate, apolymethacrylate, a polyester, or any combination thereof. In oneparticular embodiment, the polymer film includes a polyethyleneterephthalate.

In one embodiment, a colorant layer can be present between the polymerfoam and the polymer film. In another embodiment, the colorant layer canbe present between the release layer and the polymer film. In yet athird embodiment, the colorant layer can be present between the polymerfoam and the release layer.

The structural glazing tape can be in the form of a roll. The polymerfoam of the structural glazing tape can have a thickness in a range ofabout 2 mm to about 12 mm. The release layer of the structural glazingtape can have a thickness in a range of about 0.003 microns to about 50microns. The adhesive layer of the structural glazing tape can have athickness in the range of about 0.01 mm to about 0.25 mm.

In one embodiment, the polymer foam can have a force to compress at 10%in a range of about 10 kPa to about 500 kPa. For example, the force tocompress at 10% can be in the range of about 50 kPa to about 300 kPa.

In another embodiment, the structural glazing tape can have a width in arange of about 3 mm to about 50 mm. The width can be in the range ofabout 6 mm to about 25 mm. In one embodiment, the structural glazingtape can have an Unwinding Peel Strength in the range of about 0.01lb/in to about 2.5 lb/in, such as in the range of about 0.1 lb/in toabout 1.5 lb/in. In another embodiment, the structural glazing tape canhave peel strength from a stainless steel panel in a range of about 1.0lb/in to about 8.0 lb/in, such as in the range of about 2.0 lb/in toabout 6.0 lb/in.

In another embodiment, a window module includes a metal frame having afirst major surface, a glass panel having a second major surface, astructural glazing tape between the first major surface of the metalframe and the second major surface of the glass panel. The structuralglazing tape includes a polymer foam tape having first and second majorsurfaces, an adhesive layer overlying the first major surface bondingthe structural glazing tape to the structural frame, and a release layeroverlying the second major surface and adjacent to the second majorsurface of the glass panel. More over the window module can include acured sealant between the first major surface of the metal frame and thesecond major surface of the glass panel and adjacent to the structuralglazing tape, the cured sealant bonding the metal frame to the glasspanel. The cured sealant can include a silicone sealant.

In one embodiment of the window module, the glass panel includes oneglass pane. In another embodiment, the glass panel can include aninsulated glass including at least two glass panes. In anotherembodiment of the window module, the metal frame includes an extrudedaluminum.

The structural glazing tape of the window can include any of thefeatures described herein.

In another aspect, a method of preparing a window module can includeproviding a metal frame having a first major surface, applying astructural glazing tape to the first major surface of the metal frame.The structural glazing tape can include a polymer foam tape having firstand second major surfaces, an adhesive layer overlying the first majorsurface for bonding the structural glazing tape to the structural frame,and a release layer overlying the second major surface. The method canfurther include positioning a glass panel on the structural glazingtape, filling a space with a curable sealant, wherein the space definedby the glass panel, the metal frame, and the structural glazing tape,and curing the sealant to bond the glass panel and the metal frametogether.

The method can further include curing the sealant includes heating thesealant to a cure temperature. In another embodiment, curing the sealantcan include reacting the sealant with moisture in the air. In yetanother embodiment, curing the sealant can include directingelectromagnetic radiation at the sealant. The electromagnetic radiationcan include ultraviolet radiation.

EXAMPLES Example 1

A glazing tape was prepared having a solvent-based release layer. Abarrier layer dispersion was prepared from aliphatic polyurethane inwater. The mixture was diluted with water to maintain a percentage ofthe solids between 10 wt % and 50 wt %, such as between 20 wt % and 40wt % and in this particular example at 32 wt %. The barrier layerdispersion was applied onto a polymer foam by gravure cylinder. Wetdeposits were between 1 micron and 40 microns in thickness, such asbetween 3 and 20 microns. The deposits were cured between 300° F. to340° F. for 1 to 3 minutes, in this particular example for 2 minutes at320° F. The barrier layer reached a thickness between 1 micron and 12microns, such as between 2 microns and 6 microns, in this particularinstance 3 microns.

A silicone release layer was applied onto the barrier layer. A siliconecoating was prepard from methylhydrogenpolysiloxane silicone polymer,polydimethylsiloxane silicone polymer and a catalyst. The ingredientswere mixed and diluted with a solvent such as methyl ethyl ketone,isopropyl alcohol, acetone, toluene, methyl isobutyl ketone, or anymixture thereof that the percent solids were between 0.25 wt % and 10 wt%, in this particular instance at 2.5 wt %. The silicone coating wasapplied onto the barrier layer by gravure cylinder and the wet depositwer 10 microns in thickness. The wet deposit was cured between 300° F.to 340° F. for 1 to 3 minutes, in this particular example for 2 minutesat 320° F. The release coating reached a thickness between 0.03 micronsand 1 micron, in this particular instance 0.25 microns.

Table 1 summarizes the peel strength in lb/in of the glazing tape having4 wt % or 2 wt % of solilds from a roll after 7 days or 24 hrs atindicated temperatures and their subsequent peel strength from stainlesssteel panels.

TABLE 1 7 days at room 24 hrs 7 days 7 days temp at 180° F. at 120° F.at −30° F. 4 wt % 2 wt % 4 wt % 2 wt % 4 wt % 2 wt % 4 wt % 2 wt %solids solids solids solids solids solids solids solids Release 0.20 ±0.02 0.41 ± 0.03 0.37 ± 0.02 0.86 ± 0.1  0.21 ± 0.02 0.61 ± 0.05 0.16 ±0.02 0.37 ± 0.04 from Roll Release 2.90 ± 0.08 3.78 ± 0.17 4.77 ± 0.524.16 ± 0.52 3.20 ± 0.24 3.65 ± 0.67 5.20 ± 0.63 3.57 ± 0.33 from steel

Example 2

A silicone release layer was applied onto the foam layer of a glazingtape. A silicone coating was prepared from methylhydrogenpolysiloxanesilicone polymer, polydimethylsiloxane silicone polymer and a catalyst.The ingredients were mixed into an aqueous acrylic co-polymer emulsionincluding hexylene glycol. The aqueous silicone coating was applied ontothe foam layer by gravure cylinder and the wet deposit were 10 micronsin thickness. The wet deposit was cured between 300° F. to 340° F. for 1to 3 minutes, in this particular example for 2 minutes at 320° F. Therelease coating reached a thickness between 1 micron and 12 microns,such as between 2 microns and 6 microns, in this particular instance 3microns.

Table 2 summarizes the peel strength in lb./in of the glazing tapehaving aqueous silicone coating from a roll after 7 days at roomtemperature and its subsequent peel strength from stainless steelpanels.

TABLE 2 7 days at room temp Release from Roll 0.44 ± 0.02 Release fromsteel 5.22 ± 0.22

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive-or and not to an exclusive-or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

What is claimed is:
 1. A method of preparing a window module,comprising: providing a metal frame having a first major surface;applying a structural glazing tape to the first major surface of themetal frame, the structural glazing tape comprising: a polymer foam tapehaving first and second major surfaces; an adhesive layer overlying thefirst major surface for bonding the structural glazing tape to thestructural frame; and a release layer overlying the second majorsurface; positioning a glass panel on the structural glazing tapefilling a space with a curable sealant, the space defined by the glasspanel, the metal frame, and the structural glazing tape; and curing thesealant to bond the glass panel and the metal frame together.
 2. Amethod of preparing a window module, comprising: providing a metal framehaving a first major surface; applying a structural glazing tape to thefirst major surface of the metal frame, the structural glazing tapecomprising: a tape having first and second major surfaces; an adhesivelayer overlying the first major surface for bonding the structuralglazing tape to the structural frame; and a release layer overlying thesecond major surface, wherein the release layer of the structuralglazing tape is adapted to releasable adhere to the glass panel suchthat the glass panel may be removed or shifted after an initialplacement without destroying the structural glazing tape; positioning aglass panel on the structural glazing tape; filling a space with acurable sealant, the space defined by the glass panel, the metal frame,and the structural glazing tape; and curing the sealant to bond theglass panel and the metal frame together.
 3. A method of preparing awindow module, comprising: providing a metal frame having a first majorsurface; applying a structural glazing tape to the first major surfaceof the metal frame, the structural glazing tape comprising: a tapehaving first and second major surfaces; an adhesive layer overlying thefirst major surface for bonding the structural glazing tape to thestructural frame; and a release layer overlying the second majorsurface, wherein the release layer substantially prevents the structuralglazing tape from bonding to itself; and wherein the structural glazingtape is free of a liner; positioning a glass panel on the structuralglazing tape; filling a space with a curable sealant, the space definedby the glass panel, the metal frame, and the structural glazing tape;and curing the sealant to bond the glass panel and the metal frametogether.
 4. The method of claim 1, wherein the glass panel comprisesone glass pane.
 5. The method of claim 1, wherein the glass panelcomprises an insulated glass including at least two glass panes.
 6. Themethod of claim 1, wherein the release layer of the structural glazingtape is adapted to releasable adhere to the glass panel such that theglass panel may be removed or shifted after an initial placement withoutdestroying the structural glazing tape.
 7. The method of claim 1,wherein curing the sealant includes heating the sealant to a curetemperature.
 8. The method of claim 1, wherein curing the sealantincludes reacting the sealant with moisture in the air.
 9. The method ofclaim 1, wherein curing the sealant includes directing ultravioletradiation at the sealant.
 10. The method of claim 1, wherein the methodfurther comprises disposing a barrier layer between the polymer foam andthe release layer.
 11. The method of claim 10, wherein the barrier layeris adapted to seal the second major surface from material forming therelease layer.
 12. The method of claim 10, wherein the barrier layer hasa thickness of at least 0.5 microns.
 13. The method of claim 10, whereinthe release layer has a thickness of at least 0.5 microns and notgreater than about 25 microns.
 14. The method of claim 1, wherein therelease layer substantially prevents the structural glazing tape frombonding to itself, and wherein the structural glazing tape is free of aliner.
 15. The method of claim 10, wherein the barrier layer includes apolyurethane, acrylic polymer, or wax.
 16. The method of claim 10,wherein the release layer is formed form a non-aqueous precursor. 17.The method of claim 16, wherein the precursor includes a release agent.18. The method of claim 17, wherein the release agent includes asilicone-based material, a fluorine-based material, a long-chainalkyl-based material, a fatty acid amide-based material, a polyvinylalcohol-based material, a silica powder material, or any combinationthereof.
 19. The method of claim 18, wherein the fluorine-based materialincludes polytetrafluoroethylene (PTFE).
 20. The method of claim 16,wherein the non-aqueous precursor includes a non-aqueous solvent.